2002 YAMAHA YZ85 oil

3 - 11
INSP
ADJ
AIR FILTER CLEANING
AIR FILTER CLEANING
NOTE:
Proper air filter maintenance is the biggest key
to preventing premature engine wear and
damage.
CAUTION:
Never run the engine without the air filter
element in place; this would allow dirt and
dust to enter the engine and cause rapid
wear and possible engine damage.
1. Remove:
lSeat
lFitting bolt 1
lWasher 2
lAir filter element 3
lAir filter guide 4
5PA30150
2. Clean:
lAir filter element
Clean them with solvent.
NOTE:
After cleaning, remove the remaining solvent
by squeezing the element.
CAUTION:
lDo not twist the element when squeezing
the element.
lLeaving too much of solvent in the ele-
ment may result in poor starting.
5PA30160
3. Inspect:
lAir filter element
Damage ® Replace.
4. Apply:
lFoam-air-filter oil or engine mixing oil
To the element.
NOTE:
Squeeze out the excess oil. Element should be
wet but not dripping.

3 - 12
INSP
ADJ
TRANSMISSION OIL REPLACEMENT
5. Install:
lAir filter guide 1
To air filter element 2.
5PA30170
6. Apply:
lLithium soap base grease
On the matching surface a on air filter ele-
ment.
5PA30180
7. Install:
lAir filter element 1
lWasher
lFitting bolt
NOTE:
Install the air filter element with its projection
a facing upward.
5PA30190
T R..2 Nm (0.2 m · kg, 1.4 ft · lb)
TRANSMISSION OIL REPLACEMENT
1. Start the engine and warm it up for several
minutes, and then turn off the engine and
wait for five minute.
2. Place the machine on a level place and
hold it on upright position by placing the
suitable stand under the engine.
3. Place a suitable container under the
engine.
4. Remove:
lOil drain bolt 1
lOil filler cap 2
Drain the transmission oil.
5PA30200

3 - 13
INSP
ADJ
TRANSMISSION OIL REPLACEMENT
5. Measure:
lTransmission oil capacity
Out of specification ® Adjust.
Oil capacity (periodic oil change):
0.50 L (0.44 Imp qt, 0.52 US qt)
6. Install:
lCopper washer
lOil drain bolt 1
5PA30210
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
7. Fill:
lTransmission oil
Recommended oil:
Yamalube 4 (10W-30) or SAE
10W-30 type SE motor oil
Oil capacity (periodic oil change):
0.50 L (0.44 Imp qt, 0.52 US qt)
8. Check:
lOil leakage
9. Install:
lOil filter cap 1
5PA30220

3 - 22
INSP
ADJ
SPROCKETS INSPECTION
1. Inspect:
lSprocket teeth a
Excessive wear ® Replace.
NOTE:
Replace the drive sprocket, rear wheel
sprocket and drive chain as a set.
5PA30480
EC369002
DRIVE CHAIN INSPECTION
1. Remove:
lMaster link clip
lJoint 1
lDrive chain 2
5PA30490
2. Clean:
lDrive chain
Place it in kerosene, and brush off as much
dirt as possible. Then remove the chain
from the kerosene and dry the chain.
5PA30500
3. Measure:
lDrive chain length (10 links) a
Out of limit ® Replace.
Drive chain length (10 links):
: 122.1 mm (4.81 in)
5PA30510
4. Check:
lDrive chain stiffness a
Clean and oil the chain and hold as illus-
trated.
Stiff ® Replace drive chain.
5PA30520
SPROCKETS INSPECTION/
DRIVE CHAIN INSPECTION

3 - 23
INSP
ADJ
DRIVE CHAIN SLACK ADJUSTMENT
5. Install:
lDrive chain 1
lJoint 2
lMaster link clip 3
CAUTION:
Be sure to install the master link clip to the
direction as shown.
aTurning direction5PA30530
6. Lubricate:
lDrive chain
Drive chain lubricant:
SAE 10W-30 motor oil or suit-
able chain lubricants
5PA30540
EC36A060
DRIVE CHAIN SLACK ADJUSTMENT
1. Elevate the rear wheel by placing the suit-
able stand under the engine.
2. Check:
lDrive chain slack
a
In the center between the drive axle and
rear wheel axle.
Out of specification ® Adjust.
NOTE:
Before checking and/or adjusting, rotate the
rear wheel through several revolutions and
check the slack several times to find the tight-
est point. Check and/or adjust chain slack with
rear wheel in this “tight chain” position.
Drive chain slack:
35 ~ 45 mm (1.4 ~ 1.8 in)
5PA30550

3 - 24
INSP
ADJFRONT FORK INSPECTION/
FRONT FORK OIL SEAL AND DUST SEAL CLEANING
3. Adjust:
lDrive chain slack
Drive chain slack adjustment steps:
lLoosen the axle nut 1 and locknuts 2.
lAdjust chain slack by turning the adjusters 3.
To tighten
® Turn adjuster
3 clockwise.
To loosen
® Turn adjuster
3 counter-
clockwise and push wheel forward.
lTurn each adjuster exactly the same
amount to maintain correct axle alignment.
(There are marks a on each side of chain
puller alignment.)
NOTE:
Turn the adjuster so that the chain is in line
with the sprocket, as viewed from the rear.
CAUTION:
Too small chain slack will overload the
engine and other vital parts; keep the
slack within the specified limits.
lTighten the axle nut while pushing down
the drive chain.
T R..
Axle nut:
110 Nm (11.0 m • kg, 80 ft • lb)
lTighten the locknuts.
5PA30560
EC36C000
FRONT FORK INSPECTION
1. Inspect:
lFront fork smooth action
Operate the front brake and stroke the front
fork.
Unsmooth action/oil leakage ® Repair or
replace.
5PA30570
EC36D001
FRONT FORK OIL SEAL AND DUST SEAL
CLEANING
1. Remove:
lProtector 1
lDust seal 2
NOTE:
Use a thin screw driver, and be careful not to
damage the inner fork tube and dust seal.5PA30580

3 - 25
INSP
ADJFRONT FORK INTERNAL PRESSURE BLEEDING/FRONT
FORK REBOUND DAMPING FORCE ADJUSTMENT
2. Clean:
lDust seal a
lOil seal b
NOTE:
lClean the dust seal and oil seal after every
run.
lApply the lithium soap base grease on the
inner tube.
5PA30590
FRONT FORK INTERNAL PRESSURE
BLEEDING
NOTE:
If the front fork initial movement feels stiff dur-
ing a run, bleed the front fork internal pressure.
1. Elevate the front wheel by placing a suit-
able stand under the engine.
2. Remove the air bleed screw 1 and release
the internal pressure from the front fork.
3. Install:
lAir bleed screw
5PA30590
T R..1 Nm (0.1 m · kg, 0.7 ft · lb)
EC36H002
FRONT FORK REBOUND DAMPING FORCE
ADJUSTMENT
1. Adjust:
lRebound damping force
By turning the adjuster 1.
Stiffer
a
® Increase the rebound damp-
ing force. (Turn the adjuster
1 in.)
Softer
b
® Decrease the rebound damp-
ing force. (Turn the adjuster
1 out.)
Extent of adjustment
Maximum Minimum
Fully turned in
position20 clicks out (from
maximum position)
5PA30600

3 - 27
INSP
ADJ
REAR SHOCK ABSORBER INSPECTION
lSTANDARD POSITION:
This is the position which is back by the spe-
cific number of clicks from the fully turned-in
position.
CAUTION:
Do not force the adjuster past the minimum
or maximum extent of adjustment. The
adjuster may be damaged.
WARNING
Always adjust each front fork to the same
setting. Uneven adjustment can cause poor
handling and loss of stability.
3. Install:
lRubber cap
Standard position:
YZ85: 10 clicks out
YZ85LW: 7 clicks out
EC36K000
REAR SHOCK ABSORBER INSPECTION
1. Inspect:
lSwingarm smooth action
Abnormal noise/unsmooth action ®
Grease the pivoting points or repair the piv-
oting points.
Damage/oil leakage ® Replace.
5PA30620